The present research work proposes an original integrated design method for robotic machining workcells.
The overall workcell design process results efficient and enables a fast system reconfiguration, guaranteeing workcell safety and reliability.
The integration of different techniques exploits both the potentialities of robot off-line programming and 3D CAD/CAE simulation, allowing the evaluation of alternative design solutions and working scenarios, to deliver an optimized system with enhanced machining accuracy, even without external devices and expensive
advanced technologies.
Due to the importance of the robot workcell alignment for high quality machining, great attention has been paid to defining on-line software procedures applied to tailored robust measuring system for an effective use of OLP to reach the tolerance conformity and the final quality.
The method has been successfully followed in a real case-study, characterized by heavy machining conditions due to hard material, big dimensions and weight.
The present case-study represents one of the first robotic high quality machining applications in Italy.
The ongoing research work will investigate engineering methods and techniques to further enhance robot accuracy in machining.
The next goal is to make this technology suitable for other application fields, like machining operation for automotive, aerospace or for other cast parts with even smaller geometrical and shape tolerances.
Acknowledgement
The authors want to express their gratitude to L.
Passoni, L. Ferrari and D. Passoni, from SIR S.p.A. (Modena, Italy), for their technical and managerial
contribution to the project, and FAR S.p.A. (Udine, Italy) for supporting the experimental tests.
The research work has been realized with the sustain of the “Interdepartmental Centre for Applied Research and Services in the Field of Advanced Mechanics and Engine Design - INTERMECH-MO.RE.”, supported by the European funds POR FESR 2007-2013 for the Emilia Romagna region.